boot DODGE NEON 1999 Service Service Manual

(12) Detach cables from cable support clip in tun-
nel above exhaust catalyst.
(13) Remove shift cable assembly from vehicle.
INSTALLATION
CAUTION: Gearshift cable bushings must not be
lubricated or the bushings will swell and split.
(1) To install, reverse removal procedure. After
cables have been replaced, cable adjustment should
be checked. Refer to cable adjustment procedure in
this section.
CAUTION: Only the crossover cable is adjustable.
The selector cable does not have any adjustment
capabilities.
GEARSHIFT CROSSOVER CABLE
ADJUSTMENT
(1) Remove shift console from vehicle.
(2) Loosen adjusting screw on crossover cable at
shifter (Fig. 12).
(3) Pin transaxle crossover lever in 3-4 neutral
position using a 1/4 inch drill bit. Align hole in cross-
over lever with the hole in the boss on the transaxle
case (Fig. 13). Be sure drill bit goes into transaxle
case at least one half inch.
(4) The shifter is spring±loaded and self±centering.
Allow shifter to rest in its neutral position. Torque
adjustment screw to 8 N´m (70 in. lbs.). Care must be
taken to avoid moving the shift mechanism off-center
during screw tightening.
(5) Remove drill bit from transaxle case and per-
form functional check by shifting transaxle into all
gears.
(6) Reinstall center shift console. Blouse boot out
around console. Seat boot lip on top of console.
GEARSHIFT MECHANISM REPLACEMENT
REMOVAL
(1) Remove shifter knob.
(2) Remove console assembly. Refer to Group 23,
Body for procedure.
(3) Remove shifter boot.
(4) Disconnect gearshift cables at shifter end.
(5) Remove the parking brake mechanism. Refer to
Group 5, Brakes for procedure.
(6) Remove the airbag control module. Refer to
Group 8M, Passive Restraint System for procedure.
(7) Remove the two remaining nuts at the base of
the gearshift mechanism (Fig. 14). Remove shifter.
INSTALLATION
(1) For installation, reverse removal procedure.
Fig. 12 Crossover Cable Adjustment Screw
Fig. 13 Crossover Lever Pin Procedure
Fig. 14 Gearshift Mechanism
21 - 6 TRANSAXLEPL
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Using light plier pressure, squeeze the clips
together at the rear of the trough.
(2) Slide the trough over the retaining pin that
locates the trough in the case.
INSTALLATION
(1) Reverse removal procedure to install oil feed
trough.
CLEANING AND INSPECTION
TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with
clean shop towels.
Inspect the gears, bearings, shafts and thrust
washers. Replace the bearings and cups if the rollers
are worn, chipped, cracked, flat spotted, or brin-
nelled, or if the bearing cage is damaged or distorted.
Replace the thrust washers if cracked, chipped, or
worn. Replace the gears if the teeth are chipped,
cracked, or worn thin. Inspect the synchronizers.
Replace the sleeve if worn or damaged in any way.
Replace the stop rings if the friction material is
burned, flaking off, or worn. Check the condition of
the synchro keys and springs. Replace these parts if
worn, cracked, or distorted.
SYNCHRONIZER
CLEAN
Do not attempt to clean the blocking rings in sol-
vent. The friction material will become contaminated.
Place synchronizer components in a suitable holder
and clean with solvent. Air dry.
INSPECT
Proper inspection of components involve:
²Teeth, for wear, scuffed, nicked, burred, or bro-
ken teeth
²Keys, for wear or distortion
²Balls and springs, for distortion, cracks, or wear
If any of these conditions exist in these compo-
nents, replace as necessary.
ADJUSTMENTS
GEARSHIFT CROSSOVER CABLE
(1) Remove shift console from vehicle.
(2) Loosen adjusting screw on crossover cable at
shifter (Fig. 136).(3) Pin transaxle crossover lever in 3-4 neutral
position using a 1/4 inch drill bit. Align hole in cross-
over lever with the hole in the boss on the transaxle
case (Fig. 137). Be sure drill bit goes into transaxle
case at least one±half inch.
(4) The shifter is spring±loaded and self±centering.
Allow shifter to rest in its neutral position. Torque
adjustment screw to 8 N´m (70 in. lbs.). Care must be
taken to avoid moving the shift mechanism off-center
during screw tightening.
(5) Remove drill bit from transaxle case and per-
form functional check by shifting transaxle into all
gears.
(6) Reinstall center shift console. Blouse boot out
around console. Seat boot lip on top of console.
BEARING ADJUSTMENT PROCEDURE
GENERAL RULES ON SERVICING BEARINGS
(1) Use extreme care when removing and install-
ing bearing cups and cones. Use only an arbor press
Fig. 136 Crossover Cable Adjustment Screw
Fig. 137 Crossover Lever Pin Procedure
PLTRANSAXLE 21 - 35
DISASSEMBLY AND ASSEMBLY (Continued)

perature in test room and on vehicle must be 21É C
(70ÉF) minimum for this test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and manifold gauge set.
(2) Set control to A/C, RECIRC, and PANEL, tem-
perature lever on full cool and blower on high.
(3) Start engine and hold at 1000 rpm with A/C
clutch engaged.
(4) Engine should be warmed up with doors and
windows closed.
(5) Insert a thermometer in the left center A/C
outlet and operate the engine for five minutes. The
A/C clutch may cycle depending on ambient condi-
tions.
(6) With the A/C clutch engaged, compare the dis-
charge air temperature to the A/C Performance Tem-
peratures Table.
(7) If the discharge air temperature fails to meet
the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures for
further diagnosis.
COMPRESSOR NOISE DIAGNOSIS
Excessive noise while the A/C is being used, can be
caused by loose mounts, loose clutch, or high operat-
ing pressure. Verify compressor drive belt condition,
proper refrigerant charge and head pressure before
compressor repair is performed.
If the A/C drive belt slips at initial start-up, it does
not necessarily mean the compressor has failed.
With the close tolerances of a compressor it is pos-
sible to experience a temporary lockup. The longer
the A/C system is inactive, the more likely the condi-
tion to occur.
This condition is the result of normal refrigerant
movement within the A/C system caused by temper-
ature changes. The refrigerant movement may wash
the oil out of the compressor.
EXPANSION VALVE
NOTE: Expansion valve tests should be performed
after compressor tests.
Liquid CO2 is required to test the expansion
valve. It is available from most welding supply facil-
ities. CO2 is also available from companies which
service and sell fire extinguishers.
Review Safety Precautions and Warnings in the
General Information section of this Group. The work
area and vehicle must be 21É to 27ÉC (70É to 85ÉF)
when testing expansion valve. To test the expansion
valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports.
(2) Disconnect wire connector at low pressure cut-
off switch (Fig. 10). Using a jumper wire, jump ter-
minals inside wire connector boot.
A/C PERFORMANCE TEMPERATURES
Ambient Temperature 21ÉC
(70ÉF)26.5ÉC
(80ÉF)32ÉC
(90ÉF)37ÉC
(100ÉF)43ÉC
(110ÉF)
Air Temperature at Left
Center Panel Outlet1-8ÉC
(34-46ÉF)3-9ÉC
(37-49ÉF)4-10ÉC
(39-50ÉF)6-11ÉC
(43-52ÉF)7-18ÉC
(45-65ÉF)
Compressor Discharge
Pressure After the Filter
Drier1034-1724 kPa
(150-250 PSI)1517-2275 kPa
(220-330 PSI)1999-2620 kPa
(290-380 PSI)2068-2965 kPa
(300-430 PSI)2275-3421 kPa
(330-496 PSI)
Evaporator Suction
Pressure103-207 kPa
(15-30 PSI)117-221 kPa
(17-32 psi)138-241 kPa
(20-35 PSI)172-269 kPa
(25-39 PSI)207-345 kPa
(30-50 PSI)
Fig. 10 Low Pressure Cut-Off Switch
PLHEATING AND AIR CONDITIONING 24 - 7
DIAGNOSIS AND TESTING (Continued)

MAXIMUM HEATER OUTPUT: TEST AND
ACTION
Engine coolant is provided to the heater system by
two 16 mm (5/8 inch inside diameter) heater hoses.
With engine idling at normal running temperature,
set the control to maximum heat, floor, and high
blower setting. Using a test thermometer, check the
air temperature coming from the floor outlets, refer
to Temperature Reference Table.
If the floor outlet air temperature is insufficient,
refer to Group 7, Cooling Systems for specifications.
Both heater hoses should be HOT to the touch (cool-
ant return hose should be slightly cooler than the
supply hose). If coolant return hose is much cooler
than the supply hose, locate and repair engine cool-
ant flow obstruction in heater system.
POSSIBLE LOCATIONS OR CAUSE OF
OBSTRUCTED COOLANT FLOW
(1) Pinched or kinked heater hoses.
(2) Improper heater hose routing.
(3) Plugged heater hoses or supply and return
ports at cooling system connections, refer to Group 7,
Cooling System.(4) Plugged heater core.
(5) Air locked heater core.
(6) If coolant flow is verified and outlet tempera-
ture is insufficient, a mechanical problem may exist.
POSSIBLE LOCATION OR CAUSE OF
INSUFFICIENT HEAT
(1) Obstructed cowl air intake.
(2) Obstructed heater system outlets.
(3) Blend-air door not functioning properly.
TEMPERATURE CONTROL
If temperature cannot be adjusted with the TEMP
lever on the control panel, the following could require
service:
(1) Blend-air door binding.
(2) Faulty blend-air door cable.
(3) Improper engine coolant temperature.
(4) Faulty Instrument Panel Control.
LOW PRESSURE CUT-OFF SWITCH
The work area must not be below 21ÉC (70ÉF) to
test the compressor clutch circuit.
(1) With gear selector in park or neutral and park
brake set, start engine and allow to idle.
(2) Raise hood and disconnect low pressure cut off
switch connector boot.
(3) Using a suitable jumper wire, jump across the
terminals inside wire connector boot.
(4) If the compressor clutch does not engage, the
cycling clutch switch, wiring, relay, or fuse can be
defective. Refer to Group 8W, Wiring Diagrams.
(5) If clutch engages, connect manifold gauge set.
Read low pressure gauge. At pressure above 97 kPa
(14 psi) and above, low pressure out off switch will
complete the clutch circuit. If the low pressure gauge
reads below 140 kPa (20 psi), the system is low on
refrigerant charge or empty due to a leak. Refer to
Service±Procedures, System Leak Checking in this
section.
(6) Install connector boot on switch and repeat
Step 3. If the clutch does not engage, replace the low
pressure cut off switch.
SYSTEM CHARGE LEVEL TEST
The procedure below should be used to check
and/or fill the refrigerant charge in the air condition-
ing system.
Fig. 11 Evaporator Probe Harness Connector
TEMPERATURE REFERENCE TABLE
Ambient Temp.Minimum
FloorOutlet
Temp.
Celsius Fahrenheit Celsius Fahrenheit
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153É
PLHEATING AND AIR CONDITIONING 24 - 11
DIAGNOSIS AND TESTING (Continued)

(2) If previous probe was removed from top hole,
use a small plastic stick and make a new hole. Make
the hole 1/4 inch above or below the original hole in
the evaporator core.
(3) Insert new probe into hole between evaporator
fins.
(4) Reinstall rubber grommet into evaporator
probe access hole.
EXPANSION VALVE
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL
(1) Remove the boot-type wire connector from the
pressure cut-off switch.
(2) Remove the center bolt of refrigerant line
plumbing sealing plate (Fig. 31).
(3) Carefully pull the refrigerant line-sealing plate
assembly from the expansion valve towards front of
vehicle. Do not scratch the expansion valve sealing
surfaces with pilot tubes.
(4) Cover the openings on A/C line-sealing plate
assembly to prevent contamination.
(5) Remove two screws securing the expansion
valve to the evaporator sealing plate.
(6) Carefully remove valve.
INSTALLATION
(1) Remove and replace the aluminum gasket on
the evaporator sealing plate.
(2) Carefully hold the expansion valve to the evap-
orator sealing plate so not to scratch the sealing sur-
face. Install two screws and tighten to 1163 N´m
(100630 in. lbs.).
(3) Remove and replace the aluminum gasket on
the refrigerant line- sealing plate assembly.(4) Carefully hold the refrigerant line-sealing plate
assembly to the expansion valve. Install bolt and
tighten to 2363 N´m (200630 in. lbs.).
(5) Connect wires to low pressure cut-off switch.
(6) Evacuate and recharge system.
(7) After expansion valve is installed, system is
charged, and leaks have been checked, repeat A/C
performance check.
A/C FILTER/DRIER
The filter/drier is mounted in a rubber grommet on
the right side of the engine compartment. The refrig-
erant must be recovered from the A/C system before
replacing the filter/drier assembly.
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY RECOVERED BEFORE PRO-
CEEDING WITH THIS OPERATION.
REMOVAL
(1) Disconnect liquid line from filter/drier.
(2) Disconnect liquid line on suction line assembly
from filter/drier.
(3) Pull filter/drier out of rubber grommet.
INSTALLATION
For installation, reverse the above procedures.
HIGH PRESSURE CUT OUT SWITCH
WARNING: THE REFRIGERANT MUST BE
REMOVED FROM THE SYSTEM BEFORE REMOV-
ING THE HIGH PRESSURE CUT OUT SWITCH.
REMOVAL
(1) Disconnect wiring connector at the switch (Fig.
32).
(2) Remove internal snap ring.
Fig. 30 Evaporator Probe LocationFig. 31 Expansion Valve
PLHEATING AND AIR CONDITIONING 24 - 23
REMOVAL AND INSTALLATION (Continued)

LIQUID LINE
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
REMOVAL
(1) Using a R-134a refrigerant recovery machine,
remove the refrigerant from A/C system.
(2) Disconnect liquid line at drier.
(3) Disconnect liquid line at condenser.
INSTALLATION
For installation, reverse the above procedures.
LOW PRESSURE CUT OFF SWITCH
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY RECOVERED BEFORE PRO-
CEEDING WITH THIS OPERATION. REFER TO
REFRIGERANT RECOVERY SECTION.
REMOVAL
(1) Disconnect the boot like wire connector at the
cut off switch.
(2) Using a sender unit removal socket, remove the
switch from the expansion valve (Fig. 34).
INSTALLATION
NOTE: Verify the O-ring condition on the replace-
ment switch.
For installation, reverse the above procedures.
Evacuate and charge the system.
MODE CONTROL CABLE
The Mode Control Cable can be removed and
installed without having to remove the instrument
panel from the vehicle.
REMOVAL
(1) Remove instrument panel upper cowl panel.
(2) Remove right side upper instrument panel
bezel (Fig. 35).
(3) Remove center vent duct (Fig. 36).
(4) Remove upper defrost duct (Fig. 37).
(5) Remove inner defrost duct (Fig. 38).
(6) Disconnect cable at heater unit.
(7) Disconnect cable at control panel.
(8) Remove cable from vehicle.
INSTALLATION
For installation, reverse the above procedures,
adjust cable and test. Refer to Mode Control Cable
Adjustment at the end of this section.
Fig. 34 Low Pressure Cut-Off Switch and Expansion
Valve ± Typical
Fig. 35 Bezel Removal
Fig. 36 Instrument Panel Center Vent
PLHEATING AND AIR CONDITIONING 24 - 25
REMOVAL AND INSTALLATION (Continued)